The Boeing Company

Other

Christopher Mark Vaccaro

Roger W Engelbart

April L Beisiegel

David A Lilienthal

Nancy L Wood

Jeffrey J Kilwin

James Leonard Scherer

George E Bible

Brian Stutzman

Elizabeth Ann Paton

Douglas Duane Trimble

Richard J Steckel

John Robert Dworschak

Scott Edwin Black

Ronald J Newcomer

Ron DeFonce

Ron Newcomer

William A Lane

Douglas D Trimble

Apparatus, systems, and methods for the inspection of holes in transparent materials, the apparatus including a processor, an illumination probe, and a detection probe. The illumination probe includes a laser light source and a reflective surface and is configured to be inserted into a first hole in the transparent material. The detection probe includes a second reflective surface and a photodetector and is configured to be inserted in a second hole in the transparent material. Laser light is directed onto the first reflective surface within the first hole and is reflected through a wall of the first hole, into the transparent material, and reflected by the second reflective surface to the photodetector. The photodetector transmits a measured light intensity value to the processor, which compares the light intensity value to a standard intensity value to determine whether or not a crazing condition exists in the second hole.

Apparatus, systems, and methods for the laser inspection of holes in transparent materials

A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness. The shim may be applied between the part surfaces. The parts may be fitted and assembled together.

Predictive surface adjustment for joint assembly

Methods, systems, and apparatus for detection of a condition in a hole defined by a transparent material that is at least partially enclosed by one or more substantially opaque materials. The method may include positioning a light source in a first hole in the transparent material, directing light from the positioned light source through the transparent material and toward a second hole that is adjacent to the first hole. A prism may be positioned so that the light transmitted from the light source through the machined inner surface of the second hole is visible through a viewing face of the prism. By observing the transmitted light, a surface condition of the machined inner surface of the second hole may be determined.

Methods, apparatus, and systems for inspecting holes in transparent materials

A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.

Predictive shimming of joints

A method and apparatus for inspecting a composite structure. A thickness profile of a portion of a region of a composite structure is identified. The region has a cross-section with non-parallel surfaces. An estimated thickness for a location within the region and outside of the portion is identified using the thickness profile. An indication of whether the location has undesirable porosity is generated based on information about attenuation of response sound signals and the estimated thickness for the location.

Porosity inspection system for composite structure with non-parallel surfaces

A method and apparatus for inspecting a composite structure. A response sound signal to a sound signal sent into the composite structure at a location on the composite structure is detected. An attenuation is identified in the response sound signal detected in response to the sound signal sent into the composite structure at the location on the composite structure. An indication of whether additional evaluation of the location is needed based on a comparison of the attenuation in the response sound signal to a baseline attenuation value for porosity for the location on the composite structure is generated.

Porosity inspection system for composite structures

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate, such as a metallic interleaved composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness, at least one metallic shim, and at least one mesh. A plurality of metallic shims and meshes may be disposed in alternating layers within the member. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the metallic shim may aide in modeling a metallic laminate. The manufactured reference standard may replace more costly porous, fiber-reinforced, composite reference standards, such as porous metallic interleaved composite laminate reference standards, in the aircraft industry and in other non-aircraft applications.

Pseudo porosity reference standard for metallic interleaved composite laminates

The invention relates to tapered reference standards, and methods for their manufacture and use. An ultrasonic inspection reference standard for tapered, composite materials may include a member having at least one tapered section. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The tapered reference standards may substantially mimic the affect on ultrasonic sound passing through tapered sections in composite laminates.

Tapered ultrasonic reference standard

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh produces a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. The manufactured reference standard may replace more costly porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Porosity reference standard utilizing a mesh

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness. The member may be defined by at least one hollow, non-spherical shaft. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The non-spherical shaft may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Porosity reference standard utilizing one or more hollow, non-cylindrical shafts

The embodiments of the disclosure relate to a method of displaying an image of an inconsistency on a part. The part may be scanned. An inconsistency on the part may be located. An image of the inconsistency may be displayed on the part. In other embodiments, parts are provided which had images of the parts' inconsistencies displayed on one or more surfaces of the parts.

Automated imaging of part inconsistencies

The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a cored composite laminate having porosity. An ultrasonic inspection reference standard for cored composite laminates having porosity may include a member having at least one thickness, at least one core, and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the core may aide in modeling a cored composite laminate. The manufactured reference standard may replace more costly porous, cored, composite laminate reference standards in the aircraft industry and in other non-aircraft applications.

Pseudo porosity reference standard for cored composite laminates

The disclosure relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one discrete wire. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The discrete wire may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Porosity reference standard utilizing one or more discrete wires

A system and method for identifying defects in a workpiece are provided. The system includes a sensor for non-destructive testing. The system also includes a movable arm carrying the sensor and being pivotally attached to a base. The movable arm includes at least one pivotable joint between the base and the sensor, and is capable of being moved such that the sensor acquires data indicative of a workpiece as the sensor travels proximate to the workpiece. A data acquisition system is capable of communicating with the sensor to create an image of at least a portion of the workpiece based on the data acquired by the sensor.

Inspection system using coordinate measurement machine and associated method

Systems and methods for detecting discontinuous fibers in composite laminates are disclosed. In one embodiment, a method includes transmitting an incident ultrasonic signal onto a front surface of a composite laminate at a plurality of locations over an area of interest, receiving a full waveform at each of the plurality of locations over the area of interest, storing the full waveform at each of the plurality of locations over the area of interest, and analyzing the full waveform at each of the plurality of locations over the area of interest for an amplitude distortion indicative of a fiber discontinuity within the composite laminate, including selecting a gate value corresponding to a depth location within the composite laminate and displaying a C-scan image of an amplitude value from the full waveform at the plurality of locations over the area of interest.

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O'Fallon, MO, United States of America

Christopher Mark Vaccaro